System and method to fuse bone

ABSTRACT

An implant is provided that is operable to be disposed between and fuse two sections of a bone. The implant includes a material that is operable to abut against the two sections of the bone. The material is porous and/or fibrous and is operable to receive at least one cellular growth factor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/517,276, filed in the U.S. Patent and Trademark Office on Jul. 19,2019, which claims the benefit of U.S. Provisional Patent ApplicationNo. 62/700,378, filed in the U.S. Patent and Trademark Office on Jul.19, 2018, each of which is incorporated herein by reference in itsentirety for all purposes.

BACKGROUND 1. Field of the Invention

The present inventive concept relates to systems and methods to healand/or replace bone. In at least one example, the present inventiveconcept relates to an implant system and method to stabilize and fusetwo halves of a sternum in a patient post-sternotomy.

2. Description of Related Art

Physical intervention in tissue of a human or an animal, for examplesurgery, dates to prehistoric times. During a surgical procedure, anincision is made to access the interior of the body and when theprocedure is complete, the incision is closed to the externalenvironment. Some parts of the body are not directly accessible via asimple incision and present additional challenges. For example, organssuch as the heart and lungs are protected within the ribcage/thoraciccage. Thus, to access a patient's heart, a surgeon often needs toseparate the sternum.

The sternum or breastbone is a long, flat bone forming the middleportion of the front of the chest. Individual rib bones are connectedalong the sides of the sternum via cartilage to form theribcage/thoracic cage which protects the heart, lungs, and major bloodvessels from injury. The sternum is cut open in a sternotomy to gainaccess to the thoracic contents when performing cardiothoracic surgery.

A sternotomy is a surgical procedure in which a midline longitudinalincision is made through at least a portion of the sternum to allowopposing halves/portions to be laterally separated to provide access toorgans within the ribcage/thoracic cage. When the surgical procedure iscomplete, the separated halves/portions are aligned with and secured toone another and the incision closed. A variety of devices, compositions,and methods for assisting with closing and healing of sternotomy woundscan be utilized.

The ideal goal for assisting with closing and healing of sternotomywounds is complete rejoining of sternal portions with new bone growth inthe absence of complications. Unfortunately, patient recovery from aconventional sternotomy is often slow and problematic. As the twosections (of the sternum) are brought back together by the surgeon,proper compression and a tight realignment of the end plates of thesternal surfaces is rarely achieved resulting in non-union, i.e.dehiscence, of separated sternal halves. This non-union allows formotion such as sliding of the surface of one sternal half against thesurface of the other sternal half leading to significant pain for thepatient and increased chance for development of infection. Additionally,the lack of proper compression leads to the formation of fibrous scartissue instead of the desired new bone. If further surgical proceduresare required, the scar tissue will have to be removed furthercomplicating the procedure.

Accordingly, there is a need for an improved system and method to reduceor eliminate the above-described shortcomings which will move one closerto the goal of a sternum completely healed by new bone growth.

SUMMARY

The present inventive concept provides a system and method to fuse bonewhich has been separated or fractured into two sections. An implant isprovided to be disposed between the two sections of the bone. Theimplant includes an inner layer including a cortical bone graft and anouter layer at least partially surrounding the inner layer. The implantis sized and shaped such that substantially all of the split surfaces ofthe two sections are compressed against the implant. Accordingly, theimplant can accelerate and promote fusion of the bone.

The aforementioned may be achieved in an aspect of the present inventiveconcept by providing an implant operable to be disposed between and fusetwo sections of a bone. The implant may include an inner layer and anouter layer. The outer layer may at least partially surround the innerlayer and may be operable to abut against the two sections of the bone.The outer layer may be porous and/or fibrous and may be operable toreceive at least one cellular growth factor.

The outer layer may include a first portion and a second portion. Theinner layer may be sandwiched between the first and second portions ofthe outer layer. The outer layer may be wrapped around a circumferenceof the inner layer.

The inner layer and/or the outer layer may include tissue, for examplebone tissue. The inner layer and/or the outer layer may include at leasta portion of at least one of the following: cortical bone fibers,cancellous bone fibers, collagen sponge, cortical bone graft, syntheticbone, and/or tissue graft. The at least one cellular bone growth factormay include bone morphogenetic proteins, mesenchymal stem cells, blood,osteoclasts, osteoblasts, antibiotics, analgesics, and/or medications.The inner layer may be fenestrated to promote bone growth.

The implant may have a thickness between about 2 millimeters and about100 millimeters, alternately between about 2 millimeters and about 50millimeters, alternately between about 2 millimeters and about 25millimeters. The implant may have a length between about 25 millimetersand about 250 millimeters, alternately between about 25 millimeters andabout 150 millimeters, alternately between about 25 millimeters andabout 75 millimeters. The implant may have a depth between about 1millimeters and about 30 millimeters, alternately between about 1millimeters and about 20 millimeters, alternately between about 1millimeters and about 10 millimeters.

One or more tacks may extend from at least one of the inner layer or theouter layer and may be operable to couple with the bone. The one or moretacks may include bone tissue, vicryl, polypropylene, stainless steel,titanium, polyether ether ketone (PEEK), polyetherketone (PEK),polymers, metals, and/or poly(methyl methacrylate) (PMMA).

The inner layer may include two tabs which extend from each end of theouter layer. The tabs may be operable to provide compression andstability to assist in anchoring the implant between the two sections ofthe bone.

Also, the aforementioned may be achieved in an aspect of the presentinventive concept by providing a method to fuse two sections of a bone.The method may include disposing an implant between the two sections ofthe bone. The implant may include an inner layer and an outer layer. Theouter layer may at least partially surround the inner layer and may beoperable to abut against the two sections of the bone. The outer layermay be porous and/or fibrous and may be operable to receive at least onecellular growth factor. The implant may be compressed between the twosections of the bone such that the outer layer is abutting against thetwo sections of the bone. The compression of the implant and the twosections of the bone may be secured so that one or more loads arecreated. The one or more loads may be one or more forces acting on,e.g., opposing, at least one side of the two sections of the bone oreach of the two sections of the bone. The one or more loads may beequally or unequally exerted on each of the two sections of the bone.The compression of the implant and/or the two sections of the bone maybe secured using one or more securing elements, e.g., one or morefasteners such as a wire. The one or more securing elements may provideor at least supplement the one or more loads acting on or opposing bothof the two sections of the bone. In this manner, the one or moresecuring elements may be one or more load-creating elements.

The inner layer and/or the outer layer may include tissue, for examplebone tissue. The inner layer and/or the outer layer may include at leasta portion of at least one of the following: cortical bone fibers,cancellous bone fibers, collagen sponge, cortical bone graft, syntheticbone, and/or tissue graft. The method may further include soaking theimplant in the at least one cellular growth factor. The at least onecellular bone growth factor may include bone morphogenetic proteins,mesenchymal stem cells, blood, osteoclasts, osteoblasts, antibiotics,analgesics, and/or medications. The inner layer may be fenestrated topromote bone growth.

The implant may have a thickness between about 2 millimeters and about100 millimeters, alternately between about 2 millimeters and about 50millimeters, alternately between about 2 millimeters and about 25millimeters. The implant may have a length between about 25 millimetersand about 250 millimeters, alternately between about 25 millimeters andabout 150 millimeters, alternately between about 25 millimeters andabout 75 millimeters. The implant may have a depth between about 1millimeters and about 30 millimeters, alternately between about 1millimeters and about 20 millimeters, alternately between about 1millimeters and about 10 millimeters. The method may include cutting theimplant to a predetermined thickness, length, and/or depth.

The implant may be coupled with the bone by inserting one or more tacksextending from at least one of the inner layer or the outer layer intothe bone. The one or more tacks may include bone tissue, vicryl,polypropylene, stainless steel, titanium, polyether ether ketone (PEEK),polyetherketone (PEK), polymers, metals, and/or poly(methylmethacrylate) (PMMA).

The foregoing is intended to be illustrative and is not meant in alimiting sense. Many features of the embodiments may be employed with orwithout reference to other features of any of the embodiments.Additional aspects, advantages, and/or utilities of the presentinventive concept will be set forth in part in the description thatfollows and, in part, will be apparent from the description, or may belearned by practice of the present inventive concept.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description,will be better understood when read in conjunction with the appendeddrawings. For the purpose of illustration, there is shown in thedrawings certain embodiments of the present disclosure. It should beunderstood, however, that the present inventive concept is not limitedto the precise embodiments and features shown. The accompanyingdrawings, which are incorporated in and constitute a part of thisspecification, illustrate an implementation of apparatuses consistentwith the present inventive concept and, together with the description,serve to explain advantages and principles consistent with the presentinventive concept.

FIG. 1 is a diagram illustrating a sternum with a separation site;

FIG. 2A is a diagram of sternal dehiscence post-surgery in which the twosections of the sternum are secured with wire fasteners;

FIG. 2B is a diagram illustrating the two sections of the sternumsecured with plates and screws;

FIG. 3 is a diagram illustrating an implant disposed between twosections of a bone;

FIG. 4 is a diagram illustrating insertion and positioning of theimplant into a space between the two sections of the sternum.

FIG. 5 is a diagram illustrating compression of the two sections of thesternum such that the implant abuts the two sections of the sternum andcloses the space therebetween.

FIG. 6 is a diagram illustrating a partially exploded example of animplant;

FIG. 7 is a diagram illustrating a partially exploded example of animplant;

FIG. 8 is a diagram illustrating a partially exploded example of animplant;

FIG. 9 is a diagram illustrating the porous nature of the outer layer;

FIG. 10 is a diagram illustrating the porous nature of the inner layer;

FIG. 11 is a diagram illustrating an example of an implant;

FIG. 12 is a diagram illustrating an example of an implant with flangesor tabs;

FIG. 13 is a diagram illustrating an implant in the shape of a wedge orshim;

FIG. 14 is a diagram illustrating an implant including fasteners ortacks;

FIG. 15 is a diagram illustrating an example of a fastener;

FIG. 16 is a diagram illustrating another example of a fastener;

FIG. 17 is a diagram illustrating an implant with bone cross-pins;

FIG. 18 is a diagram illustrating an implant with fasteners that includeteeth or barbs;

FIG. 19 is a diagram illustrating a sealed double peel-pack;

FIGS. 20A-C are diagrams illustrating a syringe with a needle having anauger-style tip being used to inject fluid into a double peel-pack;

FIG. 21 is a diagram illustrating a surface treatment for an implant;

FIGS. 22A-C are diagrams illustrating a surface treatment for animplant;

FIGS. 23A and 23B are diagrams illustrating a surface treatment for animplant;

FIGS. 24A-C are diagrams illustrating a surface treatment for animplant; and

FIG. 25 is a flow chart of a method for utilizing an implant.

DETAILED DESCRIPTION

The following detailed description references the accompanying drawingthat illustrates various embodiments of the present inventive concept.The illustration and description are intended to describe aspects andembodiments of the present inventive concept in sufficient detail toenable those skilled in the art to practice the present inventiveconcept. Other components can be utilized and changes can be madewithout deviating from the scope of the present inventive concept. Thefollowing detailed description is, therefore, not to be taken in alimiting sense. The scope of the present inventive concept is definedonly by the appended claims, along with the full scope of equivalents towhich such claims are entitled.

I. Terminology

The phraseology and terminology employed herein are for the purpose ofdescription and should not be regarded as limiting. For example, the useof a singular term, such as, “a” is not intended as limiting of thenumber of items. Also, the use of relational terms such as, but notlimited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,”“up,” and “side,” are used in the description for clarity in specificreference to the figures and are not intended to limit the scope of thepresent inventive concept or the appended claims. The term “automatic,”“automatically,” or any variation thereof is used in the description todescribe performing a subsequent action without any assistance,interference, and/or input from a human. Further, it should beunderstood that any one of the features of the present inventive conceptmay be used separately or in combination with other features. Othersystems, methods, features, and advantages of the present inventiveconcept will be, or become, apparent to one with skill in the art uponexamination of the figures and the detailed description. It is intendedthat all such additional systems, methods, features, and advantages beincluded within this description, be within the scope of the presentinventive concept, and be protected by the accompanying claims.

The term “implant” or “surgical implant” can refer to a medical devicemanufactured to replace a missing biological structure, support adamaged biological structure, or enhance an existing biologicalstructure.

The term “bone grafting,” “bone graft,” or any variation thereof canrefer to any surgical procedure for replacing missing bone and/or addingnew bone. In some examples, bone grafts can replace lost bone with newbone and/or bone tissue. In some examples, bone grafts can promotehealing, reduced pain, increased spirometer readings, improved sternalalignment and/or reduced dehiscence risks related to the stabilization,alignment, and/or fusion of two halves of a patient's sternum which havebeen separated and/or fractured, for example by sternotomy. The bonegraft can be an autograft obtained from the patient receiving the graft;an allograft obtained from a different individual of the same species asthe patient receiving the graft; a xenograft obtained from an individualof a different species as the patient receiving the graft; and/or anysynthetic bone grafts made of manufactured materials and/or imitationbone.

The term “sternotomy” can refer to the surgical procedure of cutting apatient's sternum and separating cut portions to access thoracic organssuch as the heart, lungs, and/or blood vessels. While the disclosedsubject matter is focused on the sternum, it is foreseen that the systemand method can be utilized in relation to any separated portions of anybone.

The term “patient” can include any human being or animal. The term“subject” may also be used herein to refer to the patient.

Cortical bone or compact bone can be a dense outer surface of bone thatforms a protective layer around the internal cavity of a bone. Corticalbone assists in providing body structure and weight bearing.

Cancellous bone can be a meshwork of spongy tissue of mature bone, forexample found at the core of vertebral bones in the spine and/or at theends of long bones such as the femur.

The term “bone growth-promoting material” can include any material thatpromotes and/or enhances bone growth. The term “bone growth-promotingagent” can include any composition or material that promotes and/orenhances bone growth. The bone growth-promoting agent added to theimplant can be any known bone-growth promoting agent, including, but notlimited to hydroxyapatite (HA), cellular growth factors, cytokines, andbone morphogenetic proteins (BMP). In some examples, strips of bonegrowth-promoting material, for example cancellous bone and/or collagensponge, include one or more types of living cells. The living cellsadded to the implant can be any living cells that promote and/or enhancebone growth including, but not limited to, stem cells, osteoblasts,osteoconductive cells, osteoinductive cells, and/or osteogenic cells. Insome examples, strips of bone growth-promoting material, for examplecancellous bone and/or collagen sponge, can include both bonegrowth-promoting agents and living cells as described herein.

The term “collagen sponge” can include any known collagen-containingmaterial or sponge.

The term “synthetic” material can include any man-made material. Thesynthetic material can be made from a combination of natural materialand/or man-made or fabricated material. The synthetic material may notbe found in nature.

Further, any term of degree such as, but not limited to,“substantially,” as used in the description and the appended claims,should be understood to include an exact, or a similar, but not exactconfiguration. For example, “a substantially planar surface” meanshaving an exact planar surface or a similar, but not exact planarsurface. Similarly, the terms “about” or “approximately,” as used in thedescription and the appended claims, should be understood to include therecited values or a value that is three times greater or one third ofthe recited values. For example, about 1 mm includes all values from 0.1mm to 9 mm. Additionally, the term “about” can refer to near or close tothe desired dimension, for example “about” can refer to near or close todisclosed thicknesses and encompassed thicknesses that can beeffectively implanted into the patient.

Further, as the present inventive concept is susceptible to embodimentsof many different forms, it is intended that the present disclosure beconsidered as an example of the principles of the present inventiveconcept and not intended to limit the present inventive concept to thespecific embodiments shown and described. Any one of the features of thepresent inventive concept may be used separately or in combination withany other feature. References to the terms “embodiment,” “embodiments,”and/or the like in the description mean that the feature and/or featuresbeing referred to are included in, at least, one aspect of thedescription. Separate references to the terms “embodiment,”“embodiments,” and/or the like in the description do not necessarilyrefer to the same embodiment and are also not mutually exclusive unlessso stated and/or except as will be readily apparent to those skilled inthe art from the description. For example, a feature, structure,process, step, action, or the like described in one embodiment may alsobe included in other embodiments, but is not necessarily included. Thus,the present inventive concept may include a variety of combinationsand/or integrations of the embodiments described herein. Additionally,all aspects of the present disclosure, as described herein, are notessential for its practice. Likewise, other systems, methods, features,and advantages of the present inventive concept will be, or become,apparent to one with skill in the art upon examination of the figuresand the description. It is intended that all such additional systems,methods, features, and advantages be included within this description,be within the scope of the present inventive concept, and be encompassedby the claims.

The term “coupled” is defined as connected, whether directly orindirectly through intervening components, and is not necessarilylimited to physical connections. The connection can be such that theobjects are permanently connected or releasably connected. The terms“comprising,” “including” and “having” are used interchangeably in thisdisclosure. The terms “comprising,” “including” and “having” mean toinclude, but not necessarily be limited to the things so described.

Lastly, the terms “or” and “and/or,” as used herein, are to beinterpreted as inclusive or meaning any one or any combination.Therefore, “A, B or C” or “A, B and/or C” mean any of the following:“A,” “B” or “C”; “A and B”; “A and C”; “B and C”; “A, B and C.” Anexception to this definition will occur only when a combination ofelements, functions, steps or acts are in some way inherently mutuallyexclusive.

II. General Architecture

An implant to fuse bone can be utilized, for example, at the sternumafter a sternotomy to access the heart. In some examples, the implantcan be utilized for other bones such as ribs. For example, if a surgeonaccesses the thoracic cavity by going through one or more ribs or theinner costal space, the implant can be utilized to repair the rib(s).The implant is compressed between two sections of the bone to promotebone growth and healing. Accordingly, after inserting the implantbetween the two sections of the bone, a load can be created to causecompression.

In at least one example, a leading edge of the implant may be exposed tothe vessels and heart of the thoracic cavity. The implant can becombined with an anti-adhesion membrane on the leading edge of theimplant to reduce or prevent debris from the implant from falling intothe thoracic cavity as well as to help reduce or prevent scar tissuefrom forming at that point. Accordingly, by combining the implant withthe anti-adhesion membrane, the combined tissue can act as a protectivecoating.

In at least one example, the implant can act as a carrier of othercomponents. The other components can be added to the implant eitherprior to implantation and/or after implantation. For example, the othercomponents can include, but are not limited to, plasma rich protein(PRP), bone marrow aspirate (BMA), saline, antibiotics, analgesics,anticoagulants, bone growth factors such as bone morphogenetic proteins(BMPs), hydroxyapatite, hyaluronic acids, beta-tricalcium phosphate(BTCP), surgical glues utilizing natural materials as well as humanand/or animal tissues, demineralized bone matrix (DBM) powders,particulates, pastes, putties, cancellous chips, allograft tissues,xenograft tissues, collagen fibers, collagen matrix, and/or collagenmembranes.

In at least one example, synthetic materials can be included with theimplant. The synthetic materials can include, for example, titanium,stainless steel, PEEK, PEKK, surgical grade plastics of any kind,polyethylene, polymethylmethacrylate, vicryl surgical glues, syntheticsurgical glues, porcelain, ceramics, and/or BioGlass. Other suitablesynthetic materials which are bio-compatible can also be includedwithout deviating from the scope of the invention. In some examples,bone materials and synthetic materials can be combined as desired.

The implant can be packaged in any suitable packaging without deviatingfrom the scope of the invention. For example, the implant can bepackaged in a double peel pack that allows for sterile and protectedstorage of the implant. In at least one example, the packaging can allowfor sterile and protected rehydration of the implant. The implant can berehydrated, for example, with PRP, BMA, saline, blood draw, antibiotics,analgesics, blood clotting agents, DBM liquids, DBM powders, BMPs, anysynthetic material, any manmade material, and/or any combination of theabove.

For implantation, the bone wound, such as a sternal wound, is measured.The implant can be rehydrated and trimmed to size according to thesternal measurements. The implant can be applied to the sternal edge,for example by using forceps. In at least one example, one or morevicryl stitches or tacks can be used to anchor the graft to the edge ofthe sternum. Other suitable fasteners or anchors can be utilized, forexample, vicryl tack; vicryl suture; human and/or animal suturematerial; synthetic suture material; bone tack, plug, and/or anchor;stainless steel tack, plug, and/or anchor; titanium tack, plug, and/oranchor; any other manmade or synthetic material that is used as a tack,suture, plug, and/or anchor; any natural material, human tissue, and/oranimal tissue that can be made into a tack, suture, plug, and/or anchor;DBM paste and/or putty; hydroxyapatite paste and/or putty; any suitabletype of bone glue and/or bone putty; any synthetic substance that can beused with bone and/or for bone healing that can cause the implant tostick, adhere, and/or fit onto and/or into the edge of the bone; and/orTCP paste and/or putty.

In at least one example, the implant can be press fit into the bone edgevia a natural void due to bone loss and/or poor bone quality. In someexamples, a void can be surgically created in the bone edge. In at leastone example, the implant can be secured to the bone edge with anysuitable type of surgical polymer such as polymethylmethacrylate, anyother suitable manmade adhesive substance, and/or any altered ornon-altered human and/or animal tissue. In at least one example, theimplant can be secured to the edges of the bone by utilizing wires orany other suitable closing mechanism to either support the implant, passthrough the implant, wrap the implant, suspend the implant, and/or byany other suitable closing technology that impacts the implant placementinto a position where the implant can aid in the healing and fusion ofthe bone. In at least one example, the implant can be secured to theedge of the bone with the patient's own tissue, which can be altered ornon-altered. The implant can be applied to the edge of the bone by anysuitable artificial or natural method that causes the implant to be heldin place as the bone is being closed without deviating from the scope ofthe invention.

In at least one example, peptide bone glue can be included to create aload. The peptide bone glue can be utilized with or without otherload-creating elements, such as those discussed herein. The adhesivenature of the peptide bone glue can facilitate bone growth.

The implant can be disposed in different locations in relation to thebone wound. While the sternum is discussed in the below examples, theimplant can be disposed in different locations depending on the boneand/or the wound. For example, the implant can be placed along theinside edges of the sternal bone where the sternal bone has beenincised, cut, sawed in two, or separated. In some examples, the implantcan be measured and fit to be placed and run the length of the entiresternum, for example from the jugular (suprasternal) notch of themanubrium to the distal tip of the xiphoid process. In some examples,the implant can be measured and fit into place along the inside edges ofthe manubrium only. In some examples, the implant can be measured andfit into place along the inside edges of the manubrium, through themanubriosternal joint or second costal notch and into the body of thesternum only. In some examples, the implant can be measured and fit intoplace along the inside edges of the manubrium, through themanubriosternal joint or second costal notch and into the body of thesternum, including the third, fourth, fifth, and sixth costal notches ofthe sternum to the distal tip of the sternal body only and on throughthe seventh costal notch and through the body of the xiphoid process orto the distal tip of the xiphoid process. In some examples, the implantcan be placed along the inside cut sternal edges of the sternal wound,and also be oriented in a mesh pattern to wrap the sternal edges withthe bone mesh.

To prepare the sternal edge, if the sternal edge is bleedingaggressively prior to implantation, the surgeon may choose to use ahemostatic agent along the edge of the incised sternum to help controlbleeding. By adding the implant, the surgeon can help occlude blood flowfurther. Prior to implantation, the sides of the incised sternal edgescan be roughened to help grip the implant after implantation. Forexample, the sides of the incised sternal edges can be prepared withsand paper. In at least one example, having an oversized implant made ofbone fibers allows the sternal edges to imbed into the implant. Byembedding the sternal edges into the implant, the implant acts like agasket and accomplishes at least one of the following benefits:hemostasis, pain relief, realignment, set the bone to fuse and healversus stabilizing via soft tissue or scar tissue formation, stabilizethe entire sternal construct, eliminate gapping and loosening of thesternal construct with wires. By reducing or eliminating the gaps thatmay form, the areas where bacteria can form and create infection arereduced or eliminated. After implantation of the implant, the securityof the implant can be checked, for example by palpating the entiresternal structure. In some examples, antibiotics can be added or drippedonto the implant and sternal construct. In some examples, the operativesite can be injected with pain medications to significantly reduce thepain levels post operatively.

In at least one example, co-morbidities may qualify as inclusioncriteria to use the implant. For example, the co-morbidities can includeat least one of the following: osteoporosis, diabetes, obesity, smoking,and/or vascular disease. Osteoporosis indicates poor bone quality. Withdiabetes, the body's ability to produce or respond to the hormoneinsulin is impaired. Obesity is the medical condition in which excessbody fat has accumulated to an extent that produces negative effects onthe body. Smoking leaches calcium from the skeletal system and decreasesbone density. Smoking can also have a negative effect on bone healing.Patients undergoing cardiothoracic surgery typically experience asignificant decrease in the overall quality of their health, includingvascular disease. Poor overall health decreases the viability of apatient prior to surgery and makes the patient less likely to healadequately from a large sternal wound incision. Grafting using theimplant can significantly increase the patient's ability to healappropriately post operatively.

FIG. 1 is a schematic drawing showing the interior of a human chest. Thebone 1 may be separated at separation site 2. As illustrated in FIG. 1,the bone 1 is a sternum. While the disclosure focuses on the bone 1being a sternum, in some examples, the bone 1 can be any bone that hasbeen separated into two sections that calls for fusion. Separation site2 may be an incision site 2, for example for a sternotomy. In someexamples, the separation site 2 may be the location where the bone hasbeen fractured or separated into two sections. As illustrated in FIG. 1,separation site 2 can provide a midline, longitudinal cut through atleast part of the sternum 1 such that opposing halves separate. Whileseparation site 2 is illustrated as a straight line, in other examples,separation site 2 can be any line, such as zig-zagged, diagonal, and/orirregular line without deviating from the scope of the disclosedinventive concept.

Conventionally, patient recovery from a sternotomy can be oftenproblematic due to non-union (for example mal-alignment, pain,dehiscence) of separated sections 11, 12 of the sternum 1; onset ofinfection; and/or impaired pulmonary function. Lack of properpreparation of the sternum for closure can be a factor contributing tosternal dehiscence post-surgery. As the two sections 11, 12 of thesternum 1 are brought back together, proper compression and a tightrealignment of the end plates of the two sections 11, 12 of the sternum1 is rarely achieved. Spaces and gaps remain and/or easily reopenbetween two sections 11, 12. FIGS. 2A and 2B illustrate exemplarysternums 1 for which the two sections 11, 12 are not adequately united.

FIG. 2A is a diagram of sternal dehiscence post-surgery in which the twosections 11, 12 of the sternum 1 are secured with wire fasteners 4. Thespaces and gaps 3 are present, particularly in the inset. FIG. 2B is adiagram illustrating the two sections 11, 12 of the sternum 1 securedwith plates and screws 5. Even though the sternum 1 is fused, potentialcomplications resulting from the plates and screws include difficulty inseparating the two sections 11, 12 should, for example, access to theheart is needed.

According to Wolff's Law, for bone to form properly and for the sternumto fuse shut, both time and compression (i.e. loading) needs to bepresent in the affected areas in which bone formation is desired.Wolff's Law states that bone in a healthy person or animal will adapt tothe loads under which it is placed. The biology of fracture healing is acomplex biological process that follows specific regenerative patternsand involves changes in the expression of several thousand genes. Bonehealing, or fracture healing, is a proliferative physiological processin which the body facilitates the repair of a bone fracture. Primaryhealing (also known as direct healing) requires a correct anatomicalreduction which is stable, without any gap formation. When a gap occurs,the lack of proper contact and compression along the sternal planeduring closure is a significant contributing factor to dehiscence of thetwo sections 11, 12 and other post-sternotomy complications.

A serious complication associated with sternotomy may include thedevelopment of a deep sternal wound infection (DSWI), particularlywithin spaces left due to dehiscence of the two sections 11, 12 of thesternum 1. DSWI has up to a 6% incidence of occurrence after cardiacsurgery and a potential high morbidity and/or mortality rate, whichprolongs hospital stay and significantly increases cost of care. Earlydetection and aggressive treatment with debridement, drainage, andimmediate wound closure using various mechanical methods are currentlyutilized and are necessary to prevent the development of sternal woundinfection post-surgery.

Another complication may include post-operative pain experienced by thepatient from paradoxical (i.e. abnormal) motion of the two sections 11,12 of the sternum 1, for example, when edges of the two sections 11, 12grind and/or rub together as the patient moves and/or micromovements ofthe two sections 11, 12 as the patient breathes. This pain can beproblematic as it is impossible for a patient to remain completelymotionless.

A long-lasting complication may include scar tissue formation. Becauseof the lack of proper closure and compression on the two sections 11,12, scar tissue—rather than bone—may build up causing union of the twosections 11, 12 and thus stabilizing the sternum 1. The development andbuilding up of scar tissue can be problematic, especially in situationsin which further surgical intervention is necessary. The scar tissueoften adheres to internal structures in addition to the sternum 1, suchas cardiac blood vessels. If a surgeon needs to conduct additionalsurgery, the surgeon must first remove scar tissue covering the vessels.If the scar tissue is prevalent enough, the surgeon could easily causeinjury to or even death of the patient during subsequent surgeries.

Post-operative sternal stability is an important consideration toavoiding and/or overcoming the aforementioned complications. Stabilitycan be maintained by transverse fixation of the sternum 1 by usingstainless steel wires 4 (for example as illustrated in FIG. 2A) and/ortitanium plates 5 (for example as illustrated in FIG. 2B). However, inorder to achieve such stability, proper preparation and stabilization ofthe sternum 1 is critical prior to closure of the incision. Preparationfor closure utilizing grafting can significantly improve the chances forproper healing of the sternum 1 and/or substantially reduce the amountof post-operative pain experienced by the patient, thus leading to muchquicker recovery rates.

An implant 100 can dramatically improve sternal closure andpost-operative sternal stability by providing an osteoinductive and/orosteoconductive “gasket” for sternotomy. For example, the implant 11 canfunction as a compressible packing closing any gaps between twoseparated sections 11, 12 of the sternum 1. FIG. 3 illustrates anexemplary implant 100 disposed between two separated sections 11, 12 ofbone 1, such as the sternum 1. The implant 11 provides the “gasketeffect,” as the two sections 11, 12 are brought together as shown by thearrows. By filling/closing the gaps and/or spaces that accompany sternalclosure, the chance of infection decreases, scar tissue formation isdiscouraged, and movement of the two sections 11, 12 is at least reducedto decrease post-operative pain. Furthermore, insertion of the implant100 can significantly improve compression along the surface of thesternum 1. By acting as a gasket between the two sections 11, 12, theimplant 100 can place a load on the surface areas of the two sections11, 12. Accordingly, the environment for bone healing and new boneformation can be optimized according to Wolff's Law. Thus, the implant100 can substantially reduce or eliminate the opportunity fordevelopment of sternal wound dehiscence. Further, given the objective ofthe surgeon to make up for bone loss in the sternum post sternotomy, thepresent inventive concept advantageously enables the surgeon to avoidaltering the dynamic of the thoracic skeletal system, especially as itrelates to the thoracic spine and the facet joints of the spine. Asignificant benefit to the present inventive concept is the fact that,as the surgeon wires the sternum back together and attempts to getsufficient compression, for example by tightening down wires with wireties, the implant 100 not only functions as a bone gasket, but alsofunctions to replace loss of tissue such as bone taken duringaccess/sawing process of the sternotomy. The implant 100 can more thanmake up the gap created in the sternum during this process, while alsoproviding proper compression to the sternal plane, which facilitatesfusion, and maintaining proper body mechanics, especially as it relatesto the thoracic spine and the thoracic spine facets. Without the presentinventive concept, the surgeon inadvertently and artificially loads thefacet joints of the thoracic spine in a manner that leads to early modicand degenerative changes in the articulating surface of the facetjoints.

Insertion and positioning of the implant 100 into the space between twoaligned sections 11, 12 of the sternum 1 is illustrated in FIGS. 4 and5. The two sections 11, 12 are aligned with one another, and the implant100 is positioned in between the two sections 11, 12. After insertion,as shown in FIG. 5, the two sections 11, 12 of the sternum 1 are broughttowards one another and compressed such that implant 100 abuts the twosections 11, 12 of the sternum 1 and closes the space therebetween.Sternum 1 can then be securely closed using wire 4. In other examples,other methods of fastening can be utilized without deviating from thescope of the invention.

FIG. 6 is a diagram illustrating a partially exploded example of animplant 100 operable to be disposed between and fuse two sections 11, 12of a bone 1. The implant 100 can include an inner layer 102 and an outerlayer 103 at least partially surrounding the inner layer 102 andoperable to abut against the two sections 11, 12 of the bone 1. In atleast one example, the inner layer 102 can include demineralizedcortical bone graft, for example harvested from a donor or from therecipient's own bone. As illustrated in FIG. 6, the outer layer 103includes a first portion 104 and a second portion 106. The inner layer102 can be sandwiched between the first and second portions 104, 106 ofthe outer layer 103. The inner layer 102 and/or the outer layer 103 caninclude tissue. In at least one example, the inner layer 102 and/or theouter layer 103 can include at least a portion of at least one of thefollowing: cortical bone fibers, cancellous bone fibers, collagensponge, cortical bone graft, synthetic bone, and/or tissue graft. Insome examples, the inner layer 102 and the outer layer 103 can be madeof the same material(s) such that the implant 100 is globally made ofthe same material. In some examples, the inner layer 102 and the outerlayer 103 can be made of different material(s). In at least one example,each of the first and second portions 104, 106 of the outer layer 103can expand to at least three times the depth of inner layer 102.Accordingly, the outer layer 103 can expand and fill in any spacesbetween the two sections 11, 12 of the sternum 1.

FIGS. 7 and 8 illustrate another example of the implant 100. The implant100, as illustrated in FIGS. 7 and 8 includes a spun bone wool sternalgasket harvested from human tissue. The implant 100 can be made oftissue. The implant 100 can be made from cortical bone, cancellous bone,dense cortical/cancellous bone, collagen fibers, and/or any number ofother suitable human or animal bone derived tissues. In at least oneexample, the implant 100 can include at least one cellular growthfactor. The cellular growth factors can include at least one of thefollowing: bone morphogenetic proteins (BMPs), mesenchymal stem cells,blood, osteoclasts, osteoblasts, antibiotics, analgesics, and/ormedications. In at least one example, blood can be drawn from thepatient, spun down, and added or soaked into implant 100 so that theimplant 100 becomes a carrier for the patient's own cells.

While the disclosure is focused on the implant 100 being used to fusethe two sections 11, 12 of the sternum 1 back together, for examplefollowing an open sternotomy procedure, the implant 100 can be used inother parts of the human body to aid in fusion, including, but notlimited to the ankle, foot, knee, spine, hip and SI joints, shoulder,long bones, elbow, cranium, and maxillofacial repair without deviatingfrom the scope of the invention.

In at least one example, the implant 100 can be porous and/or fibrous toreceive at least one cellular growth factor such as the cellular growthfactors discussed above. In some examples, the outer layer 103 is porousand/or fibrous and operable to receive at least one cellular growthfactor. For example, the implant 100 can include spun bone which canmake the implant 100 porous to allow blood and other fluids to easilypass through the bone fibers. This allows bone healing cells,osteoclasts and osteoblasts, naturally occurring bone morphogenicproteins and other cells, and/or added osteoconductive substances toincorporate easily throughout the implant 100. Additionally, theinclusion of the cellular growth factors can provide for significantlyquicker and greater rates of healing and fusion. The fibrous nature ofthe implant 100, such as spun bone, can function to fill voids and alsogive flexibility and compressive characteristics to the implant 100.

The porous nature of the implant 100 can also provide flexibility. Thus,the implant 100 can have the ability to adapt easily to the naturalcontours of the body. Flexibility also can allow the implant 100 toovercome challenging bone structure either created by the surgeon uponaccessing the chest cavity during entry or as a result of trauma, lossof bone, and/or other naturally occurring issues.

Another benefit of implant 100 is that it can be formed into a varietyof shapes, sizes and thicknesses to enable the surgeon to cut or trimthe implant 100 into smaller sections or pieces. In at least oneexample, particularly useful for sternal applications, the implant 100can have the general shape of a rectangular parallelepiped in which thelength has the longest dimension and the thickness has the shortestdimension so that the implant 100 can be placed against the incised wallof the sternum 1 where it will act as a “fusion gasket and/or voidfiller” to accomplish, among other things, at least one of the followingactions.

Bone Fusion Gasket: the implant 100 can provide a fusion matrix, voidfiller, and/or gasket that can accelerate and promote fusion of thesternum following an open sternal procedure. This accelerated healingcan promote bone fusion to occur and at least reduce the development ofscar tissue. Often, patients develop scar tissue that forms after anopen sternal procedure and not bone formation. Implant 100 promotes bonefusion and healing to occur.

Post-Op Pain Management: the implant 100 can act as a buffering platformto help reduce post-operative pain caused by coughing and movement.Since the chest wall moves when a patient coughs post-operatively, theragged edges of the incised bone translates against itself. Thistranslation can cause exposed and raw nerve endings to become severelyirritated and can produce massive amounts of pain. The implant 100 cancushion, shield, and protect the exposed nerve endings and buffer thetranslational forces to significantly reduce post-operative pain.

Sternal Wound Dehiscence: sternal wound dehiscence is the condition thatoccurs when a patient's sternum gets infected after an open sternalprocedure. The result is a very costly post-operative treatment with a50% morbidity rate. Implant 100 can include a live cellular matrix thatwill promote bone formation and healing. In addition, implant 100 canact as a carrier for at least one cellular growth factor such as bonemorphogenetic proteins, mesenchymal stem cells, blood, osteoclasts,osteoblasts, antibiotics, analgesics, and/or medications.

Spirometer Readings: post-operative breathing following an open sternalprocedure can be very difficult and painful for the patient.Post-operative air capacity in the lungs is critically important for apatient to make a full and healthy recovery from surgery. Patients arereluctant to take full breaths following and open sternal procedurebecause it can be very painful. Pain is generated from the sternalincision as the chest wall “books” open and closed as the lungs inflateand deflate with breathing. Because the patients may be reluctant totake full breaths because of the pain, some patients develop pneumoniapost operatively. The implant 100 can act as a dampening device and givethe chest wall added cushion and material capacity to allow andencourage the patient to take deep, post-operative breaths. Thus, theimplant 100 can help the patients increase their spirometer readings dueto the reduction in pain as well as the added material aiding the chestwall in the expansion and contraction of the lungs.

Compression and Wolff's Law: As discussed above, bone needs two factorsto fuse and heal appropriately, time and compression. Proper compressionacross the sternal plane post-operatively is extremely difficult toachieve because horizontal forces act on the sternum 1 rather thanvertical forces. Gravity plays a very necessary role in proper bonehealing and function. Gravity loads the skeletal system under normalconditions and this force allows bone cells to form and replace oldcells. In the absence of gravity force, bone does not heal well or atall, which can lead to the development of soft tissue or scar tissueinstead of bone fusion. When the bone has a vertical separation site,the forces of gravity may not distribute load adequately to such anseparation site. Instead, the surgeon typically relies on using wireties to close and give compression to the chest wall post-operatively.Since the wire ties are harder and denser that the surrounding bone, asurgeon cannot over tighten these wires as it will cause a stress riseragainst the bone and tear through the bone tissue upon excessivetightening. Because of this, the amount of horizontal compressionapplied to the wound is not adequate to satisfy Wolff's Law. Theresimply may not be enough compression applied to cause adequate fusion ofthe bone. In at least one example, the thickness of the implant 100 cancompensate for any amount of bone lost, for example to the surgeon'ssternal saw used to open up the patient. Typically, about 3 millimetersof bone may be lost to the width of the sternal saw. The thickness ofthe implant 100 can be thicker than the gap left by the saw. In at leastone example, the implant 100 can be slightly oversized, flexible, andcompressible. As the surgeon applies the wire ties or other mechanicalsternal closure devices, the added material in the sternal wound fromthe implant 100 can be adequate to cause Wolff's Law to engage. Propercompression can now be achieved without excessive tightening of wireties or closure devices.

As shown in FIGS. 7 and 8, the implant 100 can include an inner layer102, for example including a shaved bone strip and/or a cortical bonegraft, sandwiched between two portions 104, 106 of outer layer 103. Theouter layer 103 can include fragmented, prepared, and spun cortical,cancellous and dense cancellous allograft or xenograft bone fibers. Forexample, the outer layer 103 can include the TRINITY tissue formavailable from Orthofix (Lewisville, Tex.) and MTF (Edison, N.J.).

FIG. 9 shows the porous nature of the outer layer 103. Shaved bone strip103 can be an allograft or xenograft demineralized cortical bone graftharvested from a donor, or from the recipient's own bone. In at leastone example, as illustrated in FIG. 10, the inner layer 102 can includea strip of bone that is also porous. The bone strip of the inner layer102 can provide structural integrity. In at least one example, the innerlayer 102 can be fenestrated to promote bony ingrowth.

As previously discussed, because of the porous and fibrous nature ofimplant 100, the implant 100 can act as a carrier for cellular growthfactors such as, bone morphogenetic proteins, mesenchymal stem cells,blood, osteoclasts, osteoblasts, antibiotics, analgesics, and/ormedications or materials a surgeon feels are appropriate to use in thetreatment of the patient.

As illustrated in FIGS. 6-8, the inner layer 102 and the outer layer 103are each substantially rectangular prism in shape. For example, theouter layer 103 can have substantially the same length as the innerlayer 102. In some examples, the inner layer 102 and/or the outer layer103 can be ovoid, spherical, wedge or shim (as illustrated in FIG. 13),and/or any other suitable shape without deviating from the scope of theinventive concept.

FIG. 11 illustrates an example of an implant 100 with a rectangularprism shape. Additionally, FIG. 11 illustrates an example of an implant100 where the outer layer 103 is wrapped around a circumference of theinner layer 102. In at least one example, for example sternalapplications, the implant 100 can have a thickness T from about 2millimeters to about 100 millimeters, depending upon the anatomy of thepatient and the preference of the surgeon. Alternately, the implant 100can have a thickness T from about 2 millimeters to about 50 millimeters;alternately from about 2 millimeters to about 25 millimeters. In someexamples, the implant 100 can have a thickness T from about 26millimeters to about 50 millimeters. In some examples, the implant 100can have a thickness T from about 51 to about 100 millimeters. In atleast one example, the implant 100 can have a length L between about 7inches and about 11 inches. Alternately, the implant 100 can have alength L of about 9 inches. In at least one example, the implant 100 canhave a length L between about 25 millimeters and about 250 millimeters;alternately between about 25 millimeters and about 150 millimeters;alternately between about 25 millimeters and about 75 millimeters. In atleast one example, the implant 100 can have a length L between about 76millimeters and about 150 millimeters; alternately between about 151millimeters and about 250 millimeters. The depth W of the implant 100can be from about 0.5 inches to about 2 inches, again depending upon theanatomy of the patient and the preference of the surgeon. Alternately,the depth W of the implant 100 can be from about 1 inches to about 1.5inches. In at least one example, the depth W of the implant 100 can bebetween about 1 millimeters and about 30 millimeters; alternatelybetween about 1 millimeters and about 20 millimeters; alternatelybetween about 1 millimeters and about 10 millimeters. In at least oneexample, the depth W of the implant 100 can be between about 11millimeters and about 20 millimeters; alternately between about 21millimeters and about 30 millimeters. In some examples, the implant 100can be cut into segments to accommodate the different anatomy of eachpatient or to the preference of the surgeon.

FIG. 12 shows another example of an implant 100. Similar to the implants100 discussed above, the implant 100 illustrated in FIG. 12 includes aninner layer 102 and an outer layer 103 at least partially surroundingthe inner layer 102. As illustrated in FIG. 12, the inner layer 102 issandwiched between two portions 104, 106 of the outer layer 103. In atleast one example, the inner layer 102 can be a denser form of the bonewool used in the outer layer 103. In other examples, the outer layer 103can be denser than the inner layer 102. In at least one example, theinner layer 102 can be softer than the outer layer 103. In otherexamples, the inner layer 102 can be harder than the outer layer 103. Inthe implant 100, flanges or tabs 200 of the inner layer 102 can extendfrom the outer layer 103. While FIG. 12 illustrates flanges or tabs 200extending from both sides of the outer layer 103, in some examples, theflanges or tabs 200 can extend from only one side of the outer layer103. The flanges or tabs 200 of implant 100 can provide addedcompression and stability to help anchor along the incised edge of thesternum 1. The flanges or tabs 200 can create additional surface areaand central compression along the incised sternal plane. This addedfeature helps ensure graft stability, position and integrity as theimplant 100 is applied to the wound.

FIG. 13 is a diagram illustrating an implant 100 in the shape of a shim.Implant 100, as a shim, provides added compression to the sternal planeonce the sternal wires and or fusion gasket have been applied. Theimplant 100 can be cut, trimmed or otherwise shaped to size. The implant100, in the shape of a shim, can be used to either augment additionalimplants 100 that may be the same or different shapes and/or sizes toprovide compressive structure to areas where there are slight gapsbetween the outer layer 103 and the edge of the sternum 1.Alternatively, the implant 100 can be used as a stand-alone implant 100of the desired shape and size to provide compressive integrity along theseparated sternal plane. Accordingly, the implant 100 can createstability in the sternum 1 while providing the compression necessary toinitiate fusion. Additionally, the implant 100 can help prevent thesternal wound “booking” during respiration as well as sternal wound“translation” during coughing episodes by minimizing or eliminatingmicro gaps that are created by sternal saws during the openingprocedure.

It is foreseen for any example of the implant 100 that the implant 100can be made of only the inner layer 102, only the outer layer 103, or acombination of the inner layer 102 and the outer layer 103. Thecombination may be a uniform combination of the inner layer 102 and theouter layer 103. In some examples, the inner layer 102 and the outerlayer 103 can be made of the same material(s) such that the implant 100is globally made of the same material. In some examples, the inner layer102 and the outer layer 103 can be made of different material(s).

Compression across the sternal plane can be achieved in order to createfusion. The implant 100 can provide the desired compression by making upthe gap upon access into the chest cavity. For example, the sternal sawcan cause a gap of about 3 millimeters. By providing a greater amount ofbone material along the vertical axis of the incised sternum 1, as thesurgeon brings the two sections 11, 12 of the split sternal bone backtogether with the wire ties, the surgeon no longer needs to make up thegap left by the sternal saw. The implant 100 can bridge that gap andprovide more bone material to initiate fusion due to the compressionbeing exerted on the two sternal sections 11, 12 which not previouslyavailable with wire closure alone.

The basic technique of wiring the sternum closed has not changed or beentruly examined since its inception in the 1950's. Cardiovascularsurgeons are soft tissue specialists—not orthopedic specialists. Theircurrent gold standard technique of sternal closure isn't functional forbone healing and the long-term health of the patient. The wound createdto access the chest cavity can be the most problematic aspect of theentire procedure. Therefore, viewing the treatment and closure of thesternum as a “reconstruction” is vital to the success, safety and healthof the patient. Therefore, implant 100 is being termed and viewed as aSternal Reconstruction Technology because of the nature of what it'sachieving in the wound and the ultimate goal of the technique. True bonehealing requires that the conditions for cell proliferation leading tobone formation via fraction, repair and remodeling be met. By adding theimplant 100 into the incised sternal wound, proper compression andexposure to a bone fusion catalyst can be achieved.

In some examples, fasteners 300 can be used for fixation, improvedsternum positioning, and alignment. In at least one example, thefasteners 300 can couple the implant 100 to the edge of, and/or insertthe implant 100 at least partially within, the sternum 1 upon initialimplantation. FIG. 14 illustrates an implant 100 with fasteners 300. Thefasteners 300 as illustrated in FIG. 14 extend from inner layer 102and/or the outer layer 103 of the implant 100 and are operable to couplewith the bone 1. The fasteners 300 may be made of a hard material tocouple with the bone 1, while the inner layer 102 and/or the outer layer103 of the implant 100 may be a soft, malleable, and/or spongy materialto fill in any voids in the bone 1. FIG. 14 shows that the implant 100includes three fasteners 300 extending therefrom. In other examples,one, two, or more than three fasteners 300 can be included withoutdeviating from the scope of the invention.

As illustrated in FIG. 14, the fasteners 300 are tacks with hooksoperable to be inserted into the bone and couple the implant 100 withthe bone. FIG. 15 illustrates a fastener 300 with a head or cap 302where the head or cap 302 has a width or diameter larger than the bodyof the fastener 300. In some examples, the head or cap 302 can be madeof allograft bone. In other examples, the head or cap 302 can be made ofany material that the fastener 300 can be made of without deviating fromthe scope of the invention. FIG. 16 illustrates a fastener 300 in theshape of a pin where the fastener 300 does not include a head or cap.Accordingly, the fastener 300 as illustrated in FIG. 16 hassubstantially the same thickness. Additionally, as illustrated in FIG.16, the fastener 300 can have ends that taper and/or are rounded.

As illustrated in FIG. 14, fasteners 300 extend from the implant 100 onone side only. In at least one example, as illustrated in FIG. 17,fasteners 300 can be included and extend from the implant 100 on bothsides. The purpose of this cross-pinning, like that of the use offasteners 300 on one side, is to provide a structural format that willallow implant 100 to function, for example, in at least one of thefollowing manners:

-   -   1. To provide a structural, ridged platform that is coupled with        the outer layer 103 that acts as a compressive gasket. This        design can enhance stability in the sternum 1 while providing        the compression necessary to initiate fusion.    -   2. To prevent the sternal wound from booking open and closed,        for example during respiration. This can lead to scar tissue        formation and/or sternal dehiscence.    -   3. To prevent wound translation. Wound translation can occur        when the two sections of the bone rub back and forth against        each other. For example, the patient may cough post operatively        and cause the sternal edges of the wound to rub back and forth        against each other. The use of fasteners 300 can reduce the        translational forces, for example caused by coughing, movement,        and/or breathing. Reducing the translational forces can lead to        significantly reduced levels of pain, reducing the need for        post-operative pain drugs, reduced time in the ICU, and/or        recovery days spent in the hospital.    -   4. To add structural integrity back into the bone. In at least        one example, such as with a sternotomy, this can be considered a        reconstructive operative measure the surgeon is taking. The        added strength and stability can encourage faster healing rates        due to the fact that motion will be reduced across the bone, for        example the incised sternal plane.

In at least one example, to fix the implant 100 in place along theincised sternal plane, the surgeon can take any combination of thefollowing steps:

-   -   1. Clean the edges of the sternum from excess soft tissue.    -   2. Measure the length of the edge of the sternum and cut implant        100 to size, if necessary or desired.    -   3. Use an awl to punch holes in the sternal edge on one side as        to where the surgeon wants to fix implant 100 in place, if        necessary or desired.    -   4. Once the holes are created, the surgeon can pierce implant        100 with tack 300 and then press fit tack 300 and the attached        implant 100 into place along one sternal edge.    -   5. The sternum can be closed, for example using wiring        techniques. As the wires are cinched down and tightened, implant        100 is compressed between the two incised edges of the two        sections of the sternum. This process then secures implant 100        in place and helps create the compression needed for bone        growth.

The fasteners 300 can be made of one or more of the following:

-   -   1. Human Donor Bone—Allograft Tissue    -   2. The Patients Own Bone—Autograft Tissue    -   3. Animal Bone—Xenograft Tissue    -   4. Materials such as tissue for example bone tissue, vicryl,        polypropylene, stainless steel, titanium, polyether ether ketone        (PEEK), polyetherketone (PEK), polymers, metals, poly(methyl        methacrylate) (PMMA), and/or various suture and suture        materials. For example, the fasteners 300 can be formed using 3D        printed material or any version of the tissue. Other methods of        forming the fasteners 300 can be utilized without deviating from        the scope of the invention.

As shown in FIG. 18, the fasteners 300 can include teeth or barbs. Theimplant 100, as illustrated in FIG. 18, includes an inner layer 102enclosed within an outer layer 103. The outer layer 103 includes teethor barbs 300 that are integral to the inner layer 102 and/or coupledwith the inner layer 102. The length of the teeth or barbs 300 isselected so that the teeth or barbs 300 extend through the outer layer103. In some examples, the teeth or barbs 300 can extend through theouter layer 103 only when the implant 100 is compressed into place. Inother examples, the teeth or barbs 300 can extend through the outerlayer 103 even in the absence of compression. The location, shape,and/or size of the teeth or barbs 22 can be varied without deviatingfrom the scope of the invention.

In at least one example, the implant 100 can include a plurality ofinterlocking implants. The implants may include one or more modularimplants. In at least one example, the implant 100 can include aplurality of interlocking, modular implants. By providing interlockingimplants 100, a plurality of implants can be provided and interlocked tofill in any desired size and/or shape of voids in the bone 1. In someexamples, the interlocking implants can include the same materialsand/or features such that the size and/or shape of the implant 100 is asdesired. In some examples, the interlocking implants may includedifferent materials and/or features such that specific areas aretargeted as desired.

Any of the implants 100 and features discussed above can be provided inany suitable sterile surgical packaging. FIG. 19 illustrates a doublepeel pack 50. Pack 50 can package any of the implants 100 discussedabove. As illustrated in FIG. 19, in addition to the standard sealproviding the contents in a sterile environment, pack 50 includes asecondary seal 52 that includes a well or pouch 54 in which the implant100 is contained. In at least one example, the secondary seal 52 caninclude an injection port 56 above or in close proximity to the well 54.Injection port 56 can be a luer lock connection so that a syringe can becoupled to the injection port 56 and be in fluid communication with thewell 54. In other examples, the injection port 56 can be an area that ispenetrable by an injection needle. The area can be made of a material(such as the materials used for medicine vials) that resists tearing orripping after needle penetration. In at least one example, the injectionport 56 can “re-seal” after needle penetration such that fluid does notflow through the injection port 56 after the needle is removed. Pack 50provides a protected, sterile environment in which the user can safelyand effectively deliver a fluid (such as platelet rich plasma or anyother suitable cellular growth factors) to the well 54 to hydrate theimplant 100. Secondary seal 52 provides protection and restricts fluidiccommunication to and from the well 54 to allow the hydration process tooccur for the desired time.

In at least one example, bone marrow aspirate can be used to hydratebone graft implants 100. FIG. 20A illustrates an aspirating syringe 60with a needle 62 having an auguring tip 64. As illustrated in FIG. 20B,the auguring tip 64 can be used to tap into the edges of the sternum 1(or the bone marrow to be aspirated) with the specifically designedauguring effect to draw blood and cells out of this stem cell richenvironment to utilize with the implant 100. Advancing the needle tip orotherwise changing the location of the tip (for example every 2 cc's ofaspirate) can optimize retrieval of live cells. Although syringe 60,needle 62, and auguring tip 62 are designed to be used with and packagedwith pack 50, syringe 60, needle 62, and/or auguring tip 62 can be usedwithout pack 50. As illustrated in FIG. 20C, the injection needle 60 isinserted into the injection port 56. The injection needle 60 can delivera fluid, such as platelet rich plasma to hydrate the implant 100 withinthe well 54.

As is evident from this disclosure, bone contact and minimization ofmotion between the implant 100 and the two sections 11, 12 of the bone 1is important to promote fusion and to also achieve optimal clinicalresults. FIGS. 21-24 show possible surface modifications to reduceslipping and increase friction.

FIG. 21 illustrates that the outer layer 103 can include scalloping. Inat least one example, as illustrated in FIG. 21, the scalloping can beasymmetric. In other examples, the scalloping can be symmetric.

FIGS. 22A-22C illustrate microdimpled surface treatment of the outerlayer 103. Opposing portions of the outer layer 103 can be dimpled, withthe optimized dimpling of the surface divots 402 enhancing thecompressibility of the material when deployed as a biological gasket.The surface divots 402 create mesas 400. In at least one example, asillustrated in FIG. 22B, the surface divots 402 and the mesas 400 canmirror one another. In some examples, as illustrated in FIG. 22C, thesurface divots 402 and the mesas 400 can alternate.

FIGS. 23A and 23B illustrate peening and embedding of beads 500 into theouter layer 103. In at least one example, the beads 500 can includemicronized bone. In some examples, the beads 500 can includehydroxyapatite ceramics. While the beads 500 illustrated in FIGS. 23Aand 23B are spherical, the beads 500 can be any other suitable shapewithout deviating from the scope of the invention. The beads 500 arevelocity-driven to be embedded into the outer layer 103.

FIGS. 24A-C illustrate high velocity peened surface treatment. Thesurface of the outer layer 103 can be embedded with beads 600. The beads600 can include at least one of the following: nano hydroxyapatite,micro hydroxyapatite, and/or micronized cortical bone. While the beads600 illustrated in FIGS. 24A-C are spherical, the beads 500 can be anyother suitable shape without deviating from the scope of the invention.As illustrated in FIG. 24B, the beads 600 are embedded into the surfaceof the outer layer 103 by high velocity peening. The high velocitypeened surface treatment can provide a surface friction advantage asillustrated in FIG. 24C.

Other suitable surface modifications or treatments other than thosespecifically shown in FIGS. 21-24C can be utilized without deviatingfrom the scope of the invention. Additionally, any combination ofsurface modifications can be utilized without deviating from the scopeof the invention.

Referring to FIG. 25, a flowchart is presented in accordance with anexample embodiment. The method 2500 is provided by way of example, asthere are a variety of ways to carry out the method. The method 2500described below can be carried out using the configurations illustratedin FIGS. 1-24C, for example, and various elements of these figures arereferenced in explaining example method 2500. Each block shown in FIG.25 represents one or more processes, methods or subroutines, carried outin the example method 2500. Furthermore, the illustrated order of blocksis illustrative only and the order of the blocks can change according tothe present disclosure. Additional blocks may be added or fewer blocksmay be utilized, without departing from this disclosure. The examplemethod 2500 can begin at block 2502.

At block 2502, an implant 100 is disposed between two sections 11, 12 ofa bone 1. In at least one example, the bone 1 can be a sternum. In someexamples, the bone 1 can be any bone 1 which has been separated and/orfractured. The implant 100 can include an inner layer 102 including acortical bone graft. The implant 100 can also include an outer layer 103at least partially surrounding the inner layer and operable to abutagainst the two sections 11, 12 of the bone 1. The inner layer 102and/or the outer layer 103 can include tissue. In at least one example,the inner layer 102 and/or the outer layer 103 includes at least aportion of at least one of the following: cortical bone fibers,cancellous bone fibers, collagen sponge, cortical bone graft, syntheticbone, and/or tissue graft. The outer layer 103 is porous and/or fibrousand operable to receive at least one cellular growth factor. The atleast one cellular growth factor can include at least one of thefollowing: bone morphogenetic proteins, mesenchymal stem cells, blood,osteoclasts, osteoblasts, antibiotics, analgesics, and/or medications.In at least one example, the implant 100 is soaked in the at least onecellular growth factor prior to being disposed between the two sections11, 12 of the bone 1.

In at least one example, the implant 100 can have a thickness betweenabout 2 millimeters and about 100 millimeters. In at least one example,the implant 100 can have a length between about 25 millimeters and about250 millimeters. In at least one example, the implant 100 can have adepth between about 1 millimeters and about 30 millimeters. In someexamples, the implant 100 can be cut to a predetermined thickness,length, and/or depth.

At block 2504, the implant 100 can be compressed between the twosections 11, 12 of the bone 1 such that the outer layer 103 is abuttingagainst the two sections 11, 12 of the bone 1. In some examples, theimplant 100 can be coupled with the bone 1 by inserting one or moretacks 300 extending from the outer layer 103 into the bone 1. The one ormore tacks 300 can include at least one of the following: tissue,vicryl, polypropylene, stainless steel, titanium, polyether ether ketone(PEEK), polyetherketone (PEK), polymers, metals, poly(methylmethacrylate) (PMMA). In at least one example, the tissue can includebone tissue.

At block 2506, the compression of the implant 100 and the two sectionsof the bone 1 is secured. In at least one example, the compression canbe secured using wires. In some examples, the compression can be securedusing fasteners.

Clinical Evaluation Design

The study was proposed as a multicenter, observational study. The studyobjective was to evaluate an interventional “gasket” (any of theimplants disclosed herein) for repair of sternotomy wounds. Patientendpoints were defined as the proportion of subjects with relatedadverse effects. Data was represented after enrollment with follow-up of60 patients with comparison to literature-reported rates for surgicalcomplications including dehiscence, infection, and pain.

Methods

Patients undergoing open cardiac procedures at participating centerswere considered for enrollment and included if consent was obtained(n=60 patients at 3 centers). Patients were followed duringhospitalization and at a single, post-operative visit.

Experimental Approach

Dehiscence of median sternotomy wounds remains a clinical problem. Manysolutions have been developed to reduce micromotion, bridge solid bone,strengthen fixation, and reduce risk in populations who have undergonecardiac surgery. Wire cerclage closure of sternotomy is the standard ofcare despite substantial evidence of pathologic sternal displacement (>2mm) with normal physiologic strain, i.e. coughing. Post-operativefunctional recovery, respiration, pain, sternal dehiscence, andinfection are influenced by early bone stability. This study wasproposed to enhance the stability of conventional sternal closurepost-cardiotomy. The remedy was aligned to demonstrating that a flexiblebone graft will double the cross-sectional area of sternal fixationsite, supplement if not replace the bone removed during the sternotomy,and/or accentuate healing while reducing complications. Methodsaddressing instability can involve plating, wiring, cinching, grafting,with and without muscle flap coverage.

A common technical shortcoming in closing sternotomies is themisalignment of the two sections 11, 12 of the sternum 1. In a study ofpatients subjected to sternal scanning in early postoperative period,good alignment, as well as proper contact of the sternal layers, was anexception rather than a rule. Dislocation of the sternum in either theantero-posterior or in the longitudinal dimension was common, as well assternal spacing. The sternal approximation judged as “perfect” in only15% of cases when wires were used, and none when the sternum was unitedwith bands.

Recognizing that sternal stability and alignment are both factors thatdefine outcome, the implant 100 as disclosed herein takes advantage of afunctional “biological gasket” to increase the interface of the twosections 11, 12 of the sternum 1 and can, inter alia, reduce micromotionduring healing.

Rationale

The underlying concern for stabilizing sternotomy closure is adiscussion of fracture repair. Division of the sternum 1, even as acontrolled surgical procedure, still required biological repair toconsolidate the bone from either side of the sternum. Wires can be usedas a low-cost method of reducing the fracture and supporting themechanical conditions of healing. Wires offer the advantage of cohesiveforce in drawing the two surfaces together. Several factors influencethe outcome: strength of the suture material; number, location, andplacement of the sutures; and the tightness and applied stress(force/area) exerted. Unfortunately, sternal disruption can occur due tothe mechanical action of the respiratory muscles and the negativeintra-thoracic pressures associated with normal respiration. The implant100 places a structured “gasket-like” material between thehemi-sternabrae during the repair that will be compressible, double therelative surface areas of the healing bone, provide a source ofosteoinductivity and osteoconductivity, and replace the kerf of thetissue, for example bone tissue, that was lost during the cutting.

Bone repair and remodeling depends on the ensuing loading conditions. Infracture fixation, bone fragments under load experience relative motion,which determines the morphologic features of fracture repair. Perrenproposed a hypothesis whereby the tissue response to the localmechanical factors influenced the repair process which he termed the“interfragmentary strain theory.” This proposal related the tissueresponse to the local mechanical environment and integrated strain,sheer, and displacement with the physical events of fracture healing. Inits simplest consideration, interfragmentary strain is defined by themovement of fracture ends relative to the initial gap width. Althoughthe biological response of opposing bone and gap tissue has been definedwith greater resolution with the advent of precise cell biology tools,the principles governing tissue formation and transformation followingfracture still rely on sound clinical principles; fracture reduction;stable fixation; and adequate impetus to tissue regeneration. Boneregeneration occurs under tensile stress as achieved in tight appositionof adjacent bone surfaces with minimum shear force in movement. Theimplant 100 (“gasket component”) compressed between the opposing twosections 11, 12 of the sternum 1 serve to reduce the micromotion at theadjoined surfaces to prevent interfragmentary strain. Other studies haveshown that the axial loading and its effect on bone formation wasconsiderably larger at the peripheral callus and in between osteotomygaps but not in the intermedullary area. Larger peripheral callus andexcess in tissue, for example bone tissue, at the level of the gapdemonstrates more than three times larger mechanical rigidity for theaxial than for the shear group (p<0.05). In summary, fixation thatallows excessive shear movement significantly delays the healing of bonecompared to healing under axial movement of the same magnitude.

Study Design

The implant 100 improves conventional sternal closure, and may enhanceand/or accelerate post-operative recovery. Key indices of reducedpost-operative pain, less analgesic use, improved breathing and chestwall mechanics, and improved early mobility with early hospitaldischarge are important clinical targets to sternal closure techniques.Mobility and functional recovery may be delayed after sternotomy due tothe time required for osteosynthesis to be achieved through the normalhealing process (6 to 8 weeks). It is widely believed that in the periodbefore osteosynthesis occurs, sternal wires are placed under significantloading resulting in bone micromovement and substantial patientdiscomfort.

After the patients included in the study undergo sternotomy, the implant100 can be used to stabilize the two halves of the separated sternum.Stabilization creates an environment that can promote bonehealing/growth for fusion of the two sections 11, 12 of the separatedsternum 1.

CONCLUSION

In conclusion, the implants 100 described herein reduce or eliminate thedeficiencies experienced with use of conventional methods, inter alia,sternal dehiscence, infection, post-operative pain, and/or scar tissueformation, approaching the goal of a sternum completely healed by newbone growth in the absence of complications.

The disclosures shown and described above are only examples. Even thoughnumerous characteristics and advantages of the present technology havebeen set forth in the foregoing description, together with details ofthe structure and function of the present disclosure, the disclosure isillustrative only, and changes may be made in the detail, especially inmatters of shape, size and arrangement of the parts within theprinciples of the present disclosure to the full extent indicated by thebroad general meaning of the terms used in the attached claims. It willtherefore be appreciated that the embodiments described above may bemodified within the scope of the appended claims.

What is claimed is: 1-20. (canceled)
 21. An implant operable to fuse twosections of a bone, the implant comprising: at least one layer formed ofa material operable to abut against two incised edges of the twosections of the bone when the implant is disposed between the twosections of bone, the material being porous and/or fibrous and operableto receive at least one carrier component; and a plurality ofprotrusions extending from the at least one layer to mate with at leastone of the two incised edges of the two sections of the bone when theimplant is disposed between the two sections of bone.
 22. The implant ofclaim 1, wherein, the plurality of protrusions extends from a secondside of the at least one layer, opposite the first side, to mate withthe two incised edges.
 23. The implant of claim 1, wherein, theplurality of protrusions includes a plurality of flanges or tabs toanchor the implant along the two incised edges of the two sections ofbone.
 24. The implant of claim 1, wherein, the plurality of protrusionsis operable to fill a void in bone material of at least one of the twoincised edges.
 25. The implant of claim 1, wherein, the at least onelayer includes an inner layer and an outer layer, the inner layer andthe outer layer are both made of the material, the outer layer includesa first portion and a second portion, and the inner layer is sandwichedbetween the first portion and the second portion of the outer layer. 26.The implant of claim 5, wherein, the outer layer is wrapped around acircumference of the inner layer.
 27. The implant of claim 5, wherein,the plurality of protrusions is a plurality of tacks extending from theinner layer and the outer layer.
 28. The implant of claim 1, wherein,the plurality of protrusions is a series of fasteners formed of at leastone of bone tissue, vicryl, polypropylene, stainless steel, titanium,polyether ether ketone (PEEK), polyetherketone (PEK), polymers, metals,or poly(methyl methacrylate) (PMMA).
 29. The implant of claim 1,wherein, the plurality of protrusions is a series of tabs operable toprovide stability to assist in anchoring the implant between the twosections of the bone.
 30. The implant of claim 1, wherein, the materialincludes at least a portion of at least one of cortical bone fibers,cancellous bone fibers, collagen sponge, cortical bone graft, syntheticbone, and/or tissue graft.
 31. The implant of claim 1, wherein, the atleast one carrier component includes at least one of saline, bonemorphogenetic proteins, mesenchymal stem cells, blood, osteoclasts,osteoblasts, antibiotics, analgesics, or medications.
 32. The implant ofclaim 10, wherein, the at least one carrier component is harvested froma patient receiving the implant.
 33. The implant of claim 1, wherein,the material is fenestrated to promote bony ingrowth from the twoincised edges of the two sections of bone.
 34. A method to fuse twosections of a bone, the method comprising: disposing an implant with aplurality of protrusions between the two sections of the bone, theimplant including at least one layer formed of a material operable toabut against two incised edges of the two sections of the bone, thematerial being porous and/or fibrous and operable to receive at least acarrier component; compressing the implant between the two sections ofthe bone such that the plurality of protrusions engage with at least oneof the two incised edges of the two sections of the bone; and securingthe implant and the two sections of the bone.
 35. The method of claim14, wherein, the plurality of protrusions is formed along at least oneside of the at least one layer.
 36. The method of claim 14, wherein, theplurality of protrusions is uniformly spaced relative to each otheralong a side of the at least one layer.
 37. The method of claim 14,wherein, the plurality of protrusions is a series of fasteners operableto engage the two incised edges of the two sections of bone via apress-fit engagement.
 38. The method of claim 14, wherein, the pluralityof protrusions is a series of fasteners operable to couple the implantto the bone via insertion into holes formed in the bone.
 39. The methodof claim 14, wherein, the implant and the two sections of the bone aresecured together by wire.
 40. A method comprising: disposing an implantwith one or more side protrusions between two sections of bone, theimplant including at least one layer formed of a material operable toabut against two incised edges of the two sections of the bone, thematerial being porous and/or fibrous and operable to receive a carriercomponent; compressing the implant between the two sections of the bonesuch that the one or more side protrusions engage at least one of thetwo incised edges via a press-fit engagement; and securing the implantand the two sections of the bone.